Trailer Having Reduced Weight Wall Construction

ABSTRACT

A trailer wall construction having reduced weight. A trailer wall construction includes a spherical shaped corner at a juncture of three walls. Each of the walls includes at least one panel having spaced apart inner and outer shells. Another trailer wall construction includes a generally vertically extending front or side wall and a floor. The floor and front or side wall each includes at least one panel comprising spaced apart inner and outer shells. A curved connector connects a lower edge of the front or side wall to an edge of the floor. Yet another trailer wall construction includes a wall with panels attached to one another along opposing edges of the panels, each of the panels including spaced apart inner and outer shells. One connector is attached to each of the panels along a third edge. Another connector is attached to each of the panels along a fourth edge.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a division of prior application Ser. No. 11/112,489,filed Apr. 22, 2005, the entire disclosure of which is incorporatedherein by this reference.

BACKGROUND

The present invention relates generally to wall construction used intrailer assemblies and, in an embodiment described herein, moreparticularly provides a reduced weight trailer wall construction.

It is very beneficial to be able to reduce the tare weight of a trailerused commercially to haul loads. For example, bridge laws and otherregulations limit the gross weight of over-the-road vehicles. Thus, ifthe tare weight can be reduced, the weight of cargo can be increased,thereby resulting in more efficient and economical hauling operations.

Where a trailer is used to haul loose material, such as dirt, garbage,etc., it would be beneficial to provide a trailer wall constructionwhich minimizes or eliminates square corners between the walls. Thiswould prevent the loose material from being retained in the corners whenthe trailer load is dumped.

Another important consideration in trailer construction is aesthetics.It would be beneficial to be able to provide a trailer wall constructionwhich is aesthetically pleasing, both at the time it is manufactured andafter it has been in use.

Unfortunately, typical trailer wall construction methods have beenunable to adequately satisfy the needs for reduced weight, minimizedsquare corners between walls and improved aesthetics. Thus, it will beappreciated that a need exists for improved trailer wall construction.It is one of the objects of the present invention to provide to the artan improved trailer wall construction which satisfies at least one ofthe above described needs.

SUMMARY

In carrying out the principles of the present invention, a trailer wallconstruction is provided which solves at least one problem in the art.One example is described below in which a trailer wall is constructedusing multiple extruded hollow aluminum alloy panels which arehorizontally or vertically arranged in the wall. Another example isdescribed in which curved connectors are used to connect trailer walls.Yet another example is described in which a spherical shaped corner forthe trailer walls has spherical shaped spaced apart inner and outershells.

In one aspect of the invention, a trailer wall construction is providedwhich includes a spherical shaped corner at a juncture of three walls.Each of the walls includes at least one panel comprising spaced apartinner and outer shells.

In another aspect of the invention, a trailer wall construction includesa generally vertically extending front wall and a floor. Each of thefloor and front wall includes at least one panel comprising spaced apartinner and outer shells. A curved connector connects a lower edge of thefront wall to a front edge of the floor.

In a further aspect of the invention, a trailer wall constructionincludes a generally vertically extending side wall and a floor. Each ofthe floor and side wall includes at least one panel comprising spacedapart inner and outer shells. A curved connector connects a lower edgeof the side wall to a side edge of the floor.

In yet another aspect of the invention, a trailer wall constructionincludes a wall having multiple panels attached to one another, each ofthe panels having first and second edges opposite each other and thirdand fourth edges opposite each other, the panels being attached to oneanother along the first and second edges, and each of the panelsincluding spaced apart inner and outer shells. A first connector isattached to each of the panels along the third edge. A second connectoris attached to each of the panels along the fourth edge.

These and other features, advantages, benefits and objects of thepresent invention will become apparent to one of ordinary skill in theart upon careful consideration of the detailed description ofrepresentative embodiments of the invention hereinbelow and theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a panel used in a trailer wallconstruction embodying principles of the present invention;

FIG. 2 is an enlarged scale cross-sectional view of a manner ofattaching two of the panels of FIG. 1;

FIG. 3 is a rear quarter elevational view of a trailer assemblyincorporating the trailer wall construction of the invention;

FIG. 4 is a front quarter elevational view of the trailer assembly;

FIG. 5 is an isometric view of the trailer assembly with the trailerraised for dumping;

FIG. 6 is a cross-sectional view of a side wall of the trailer wallconstruction, and a juncture of the side wall with a floor of thetrailer wall construction;

FIG. 7 is a cross-sectional view of the side wall, and a juncture of theside wall with a front wall of the trailer wall construction;

FIG. 8 is a cross-sectional view of a rear post of the trailer wallconstruction;

FIG. 9 is a plan view of a spherical shaped corner of the trailer wallconstruction;

FIG. 10 is an isometric view of the spherical shaped corner;

FIG. 11 is an isometric view of an alternate trailer assemblyincorporating an alternate trailer wall construction of the invention;

FIG. 12 is a cross-sectional view of a juncture of a side wall with afloor of the alternate trailer wall construction; and

FIG. 13 is a cross-sectional view of a top connector on the side wall ofthe alternate trailer wall construction.

DETAILED DESCRIPTION

Representatively illustrated in FIG. 1 is a cross-sectional view of apanel 20 which is used in a trailer wall construction 10 (see FIG. 2)embodying principles of the present invention. In the followingdescription of the trailer wall construction 10 and other apparatus andmethods described herein, directional terms, such as “above”, “below”,“upper”, “lower”, etc., are used for convenience in referring to theaccompanying drawings. Additionally, it is to be understood that thevarious embodiments of the present invention described herein may beutilized in various orientations, such as inclined, inverted,horizontal, vertical, etc., and in various configurations, withoutdeparting from the principles of the present invention. The embodimentsare described merely as examples of useful applications of theprinciples of the invention, which is not limited to any specificdetails of these embodiments.

As depicted in FIG. 1, the panel 20 preferably consists of an integrallyformed hollow extruded item made of an aluminum alloy. However, itshould be clearly understood that other methods of constructing thepanel 20 could be used. For example, the panel 20 could be made of othermaterials, could be made up of multiple pieces joined together, etc.

The panel 20 is configured so that it has interlocking opposite edges12, 14. Extending between the edges 12, 14 are spaced apart shells 16,18. Preferably, when the panels are used in the trailer wallconstruction 10, the shell 16 is an inner shell (facing toward aninterior of the trailer) and the shell 18 is an outer shell (facingtoward an exterior of the trailer), but these positions could bereversed if desired.

The shells 16, 18 are preferably smooth, flat, plate-like structures.This provides a good appearance (for example, outer surfaces of theshells 16, 18 could be polished, etc.). In addition, if the inner shell16 is deformed or punctured, this may not be visible from the exteriorof the trailer since the outer shell 18 may not also be deformed orpunctured.

Multiple spaced apart interior webs 22 join the inner and outer shells16, 18. This strengthens the panel 20 and provides support for theshells 16, 18 between the edges 12, 14. Any number, spacing,configuration, or other arrangement of the interior webs 22 may be usedin keeping with the principles of the invention.

The manner in which the edges 12, 14 can be interlocked to join two ofthe panels 20 may be seen more clearly in FIG. 2. Note that an inwardlyextending projection 24 formed on the edge 12 is retained in a recess 26formed on the edge 14, and an outwardly extending projection 28 formedon the edge 14 is retained in a recess 30 formed on the edge 12. Thisretention of the projections 24, 28 in the recesses 26, 30 helps toprevent the edges 12, 14 from being disengaged from each other afterthey are interlocked.

To provide a rigid attachment of the panels 20 to each other, variousmethods may be used. Preferably, the inner shells 16 are welded to eachother with a weld 32 along a seam between the inner shells, and theedges 12, 14 are further adhesively bonded to each other at a flatsurface interface 34 where the edges overlap each other. Alternatively,or in addition, one or more mechanical fasteners 36 (such as blindrivets, screws, etc.) may be used at the interface 34, extending throughthe overlapping edges 12, 14.

Of course, many other methods of attaching the edges 12, 14 to eachother could be used. For example, a weld could be used in a seam 38between the edges 12, 14 to weld the outer shells 18 to each other, etc.Furthermore, the inner shells 16 and/or the edges 12, 14 could be joinedusing techniques in which friction is used to cause the structures tofuse to each other. Thus, it will be appreciated that the invention isnot limited to the attachment methods specifically described herein.

Also depicted in FIG. 2 is a method of reinforcing the shells 16, 18,for example, to prevent the shells from being damaged, to make the panel20 more rigid, etc. Specifically, a hardenable material 40 is flowed ina fluid state into a cavity 42 formed between the inner and outer shells16, 18 and the interior webs 22, and then allowed to set or harden.Although only shown in one cavity 42 in FIG. 2, if the material 40 isused to reinforce the shells 16, 18 then preferably it is used in eachof the cavities in the panels 20.

As used herein, the term “hardenable material” is used to indicatematerials which become more rigid from a flowable state. Examples ofhardenable materials include, but are not limited to, materials whichbecome rigid (such as polycarbonates, other polymers, epoxies, etc.),foamed materials, gels, etc.

Referring additionally now to FIGS. 3-5, a trailer assembly 44 isrepresentatively and schematically illustrated. The trailer assembly 44uses the panels 20 and trailer wall construction 10 described above inits walls, including two generally vertically oriented side walls 46extending between front and rear ends of the trailer, a generallyvertically oriented front wall 48, a generally vertically orientedtailgate 50, and a floor 52.

As depicted in FIGS. 3-5, the trailer assembly 44 is used to haul loosematerial, and then dump the material by elevating the front end of thetrailer while the tailgate 50 is opened. However, it should be clearlyunderstood that other types of trailers can utilize the trailer wallconstruction 10. For example, the trailer could be of the type known tothose skilled in the art as a “tipper”, the walls could form a containerwhich is releasably attached to a frame of the trailer (e.g., so thatthe container can also be transported by train, ship, etc.), the trailercould be used to haul cargo other than loose material, etc. Thus, theprinciples of the invention are not limited to the specific details ofthe trailer assembly 44 described herein.

By constructing the side walls 46, front wall 48, floor 52 and tailgate50 using the trailer wall construction 10 described above, a tare weightof the trailer assembly 44 is significantly reduced. In anotherimportant feature of the trailer assembly 44, the side walls 46 arejoined to the front wall 48, and the side and front walls are joined tothe floor 52 in a manner which reduces square corners between thesewalls, thereby providing for clearer dumping of the material transportedby the trailer.

Specifically, two curved connectors 54 are used to join a front edge ofeach side wall 46 to side edges of the front wall 48, two curvedconnectors 56 are used to join a lower edge of each side wall to sideedges of the floor 52, and another curved connector 58 is used to join alower edge of the front wall to a front edge of the floor. These curvedconnectors 54, 56, 58 are attached at junctures between the walls 46,48, 52 by two spherically shaped corners 60. In FIG. 5, the manner inwhich these features combine to provide a generally smooth interior forthe trailer assembly 44 may be seen.

Each of the side walls 46, front wall 48 and tailgate 50 includes atleast two of the panels 20. The panels 20 extend horizontally, so thatthe interlocking edges 12, 14 also extend horizontally. The floor 52includes multiple panels 20, each of which extends from side to side ofthe trailer assembly 44. However, it is not necessary for the panels 20to extend in any particular direction in the side walls 46, front wall48, tailgate 50 and floor 52, and any number of the panels may be usedin any wall of the trailer assembly 44, in keeping with the principlesof the invention.

Referring additionally now to FIG. 6, a cross-sectional view of one ofthe side walls 46 and a portion of the floor 52 is representativelyillustrated. In this view, the manner in which the side wall 46 isconnected to the floor 52 using the curved connector 56 may be clearlyseen.

A side edge 62 of the floor 52 is received in a recess 64 formed in thecurved connector 56. The floor 52 may be welded to the curved connector56 along seams therebetween and/or adhesive bonding or mechanicalfasteners may be used to attach the floor to the curved connectorgenerally as described above in relation to FIG. 2. Any method may beused for attaching the floor 52 to the curved connector 56 in keepingwith the principles of the invention.

A lower edge 66 of the side wall 46 is interlocked with an upper edge 68of the curved connector 56. The upper edge 68 of the curved connector 56is configured in a similar manner to the panel edge 14. The side wall 46may be attached to the curved connector 56 in a manner similar to thatdescribed above for attaching the panels 20 to each other andillustrated in FIG. 2. However, it should be understood that any type ofattachment method may be used in keeping with the principles of theinvention.

Note that the curved connector 56 is also similar to the panels 20 inthat it includes an inner shell 70, an outer shell 72 and spaced apartinterior webs 74 joining the spaced apart inner and outer shells. Thus,the curved connector 56 is very similar to one of the panels 20, exceptthat it is curved approximately 90 degrees along its length (each of theshells 70, 72 being radiused in a cylindrical shape, with the webs 74being radially oriented), and it has the recess 64 in place of the edge12 of the panel. If the panels 20 of the floor 52 were orientedlongitudinally, rather than laterally, in the trailer assembly 44, thenthe recess 64 could be replaced with an appropriate one of theinterlocking edges 12, 14 for attachment to the corresponding edge ofthe floor panel.

At an upper edge 76 of the side wall 46 is a top connector 78, which isalso preferably a generally hollow extruded aluminum alloy item. Theconnector 78 could include interior webs also, if desired. The connector78 has an interlocking edge 12 formed thereon for attachment to theupper edge 76 of the side wall 46, in a manner similar to that describedabove for attaching the panels 20 to each other and illustrated in FIG.2 (for example, welding, adhesive bonding, use of mechanical fasteners,etc.). However, it should be understood that any type of attachmentmethod may be used in keeping with the principles of the invention.

Several benefits are realized by the trailer wall construction asdepicted in FIG. 6. For example, the curved connector 56 and topconnector 78 are relatively light in weight and thereby serve to aid inreducing the tare weight of the trailer assembly 44, the interior of thetrailer wall construction is smooth, with sharp corners minimized, andthe exterior of the trailer is smooth and aesthetically pleasing.

Referring additionally now to FIG. 7, a cross-sectional view of aconnection between one of the side walls 46 and the front wall 48 isrepresentatively and schematically illustrated. In this view it may beseen that the curved connector 54 is used to connect a side edge 80 ofthe front wall 48 to a front edge 82 of the side wall 46. It may also beseen that the curved connector 54 is configured very similar to thecurved connector 56 described above, in that it includes the radiusedinner and outer walls 70, 72, webs 74, recess 64 on one edge andinterlocking edge 14.

An adapter 84 is used as a transition between the interlocking edge 14of the curved connector 54 and the side edge 80 of the front wall 48.The adapter 84 has a recess 90 (similar to the recess 64) to receive thefront wall panels 20 therein at the side edge 80 of the front wall 48,and an interlocking edge 12 to mate with the edge 14 of the curvedconnector 54.

The attachment methods used between the side wall 46 and the curvedconnector 54 (at the edge 82 and recess 64), between the curvedconnector and the adapter 84 (at the interlocking edges 12, 14), andbetween the adapter and the front wall 48 (at the recess 90 and edge 80)may be similar to that described above for attaching the panels 20 toeach other and illustrated in FIG. 2 (for example, welding, adhesivebonding, use of mechanical fasteners, etc.). However, it should beunderstood that any type of attachment method may be used in keepingwith the principles of the invention.

Note that it is not necessary for the adapter 84 to be used between thecurved connector 54 and the front wall 48. For example, the curvedconnector 54 could be provided with another recess 64 in place of theinterlocking edge 14, so that the front wall 48 could be received inthis other recess. An example of such a curved connector is shown inFIG. 12 and described further below.

The curved connector 58 used between the lower edge of the front wall 48and the front edge of the floor 52 may be similar to the curvedconnectors 54, 56 described above. Since the lower edge of the frontwall 48 may include an interlocking edge 12 (similar to the lower edge66 of the side walls 46), and the front edge of the floor 52 may includean interlocking edge 14 (similar to the top edge 76 of the side walls,the curved connector 58 may be provided with appropriate interlockingedges 12, 14 to mate with the front wall and floor edges, or appropriateadapters may be provided, etc. The curved connector 58 may be attachedto the front wall 48 and the floor 52 using any methods, including thosedescribed above for attaching the panels 20 to each other andillustrated in FIG. 2 (for example, welding, adhesive bonding, use ofmechanical fasteners, etc.).

Referring again to FIGS. 3-5, a rear post 86 is attached at a rear edge88 of each side wall 46. The rear post 86 serves several functions,including connecting the panels 20 at the rear edge 88 of each side wall46, providing structural support for the rear end of the side wall 46,interfacing with the tailgate 50, etc.

Referring additionally now to FIG. 8, a cross-sectional view of one ofthe rear posts 86 and a portion of the corresponding side wall 46 isrepresentatively illustrated. In this view it may be seen that the rearpost 86 is preferably an extruded generally hollow structure made of analuminum alloy, although other configurations, manufacturing methods,materials, etc. may be used in keeping with the principles of theinvention.

The rear post 86 includes a recess 92 in which the rear edge 88 of theside wall 46 is received. The rear post 86 may be attached to the sidewall 46 (at the edge 88 and recess 92) using any appropriate method,including any of those methods described above for attaching the panels20 to each other and illustrated in FIG. 2 (for example, welding,adhesive bonding, use of mechanical fasteners, etc.).

The rear post 86 widens from its forward end (at the recess 92) to itsrearward end. Preferably, an inner shell 94 of the rear post 86 isinclined toward the interior of the trailer assembly 44. Another recess96 is provided at the rearward end of the rear post 86 to receive aflange (not shown) of a frame provided about the panels 20 of thetailgate 50.

Referring additionally now to FIG. 9, the spherical shaped corner 60 isrepresentatively illustrated from a top plan view thereof. In this viewit may be seen that the corner 60 is preferably a generally hollowcasting made of an aluminum alloy, although other configurations,manufacturing methods, materials, etc. may be used in keeping with theprinciples of the invention. In FIG. 10, the corner 60 is depicted froman isometric view.

The corner 60 includes an inner generally spherical shaped shell 98, andan outer generally spherical shaped shell 100 spaced apart from theinner shell. The corner 60 is approximately one-eighth of a hollowspherical shell, having three generally flat edges 102, 104, 106 whichare orthogonal to each other. Webs 108 at corners between the edges 102,104, 106 serve to connect the inner and outer shells 98, 100.

In use, the top edge 102 is attached to a lower end of the curvedconnector 54, and each of the side edges 104, 106 is attached to an endof a corresponding one of the curved connectors 56, 58. Preferably, thecorner 60 is welded to the ends of the curved connectors 54, 56, 58, butany appropriate attachment method may be used in keeping with theprinciples of the invention.

It will be appreciated that the corner 60 provides a convenient,structurally robust, light weight and aesthetically pleasing way toconnect the curved connectors 54, 56, 58.

Referring additionally now to FIG. 11, an alternate configuration of thetrailer assembly 44 is representatively illustrated. This alternateconfiguration is similar in most respects to that depicted in FIGS. 3-5and described above, however, the side walls 46 of the alternateconfiguration have the panels 20 extending in a generally verticaldirection, instead of in a generally horizontal direction. Thisalternate configuration demonstrates that various changes may be made tothe specific trailer wall constructions described herein, withoutdeparting from the principles of the invention.

Due to the vertical orientation of the panels 20 in the side walls 46 inthe alternate configuration depicted in FIG. 11, various changes arealso made to the connectors used about the edges of the attached panels.Two of these changes are represented in FIGS. 12 and 13.

In FIG. 12 a cross-sectional view of a modified curved connector 56, andportions of the floor 52 and one of the side walls 46 are depicted. Inthis view it may be seen that the curved connector 56 has been modifiedso that it has two of the recesses 64, an upper one of which receivesthe lower edge 66 of the side wall 46 (which, due to the verticalorientation of the panels 20, no longer has the interlocking edge 12).

Similarly, in FIG. 13 a cross-sectional view of a modified top connector78 and an upper portion of one of the side walls 46 is depicted. In thisview it may be seen that the top connector 78 has been modified so thatit has one of the recesses 64 at its lower end which receives the upperedge 76 of the side wall 46 (which, due to the vertical orientation ofthe panels 20, no longer has the interlocking edge 14).

It will be readily appreciated that modifications are also made to therear post 86 and curved connector 54 to accommodate the verticalorientation of the panels 20 in the side walls 46. For example, insteadof the side walls 46 being received in the recesses 64, 92 of the curvedconnector 54 and rear post 86, appropriate interlocking edges 12, 14 maybe used. As another example, appropriately configured adapters could beused to transition from the interlocking edges 12, 14 on the side walls46 to the recesses 64, 92 of the curved connector 54 and rear post 86.

It will also be readily appreciated that any of the other walls 48, 50,52 of the trailer assembly 44 could have the panels 20 therein orienteddifferently. For example, the panels 20 in the front wall 48 andtailgate 50 could be generally vertically oriented, the panels 20 in thefloor 52 could extend front to rear, etc. The panels 20 could bediagonally or otherwise oriented in any of the walls 46, 48, 50, 52 inkeeping with the principles of the invention.

Although the trailer wall construction 10 has been described herein asbeing used in the trailer assembly 44, which is depicted as being a dumptrailer, it should be clearly understood that the trailer wallconstruction may be used in any type of trailer in keeping with theprinciples of the invention. For example, the trailer wall construction10 could be used in a trailer assembly which has a roof wall. The roofwall could be constructed of attached panels 20. As another example, thetrailer wall construction 10 could be used in a container which isreleasably attached to a trailer frame, etc.

Note that any of the generally hollow structures described herein, suchas the curved connectors 54, 56, 58, corner 60, top connector 78, andrear post 86, as well as any of the panels 20, can utilize thehardenable material 40 therein for reinforcement, reduced weight, etc.

Of course, a person skilled in the art would, upon a carefulconsideration of the above description of representative embodiments ofthe invention, readily appreciate that many modifications, additions,substitutions, deletions, and other changes may be made to thesespecific embodiments, and such changes are within the scope of theprinciples of the present invention. Accordingly, the foregoing detaileddescription is to be clearly understood as being given by way ofillustration and example only, the spirit and scope of the presentinvention being limited solely by the appended claims and theirequivalents.

1-19. (canceled)
 20. A trailer wall construction for use as part of atrailer assembly, the trailer wall construction comprising: a generallyvertically extending front wall; a floor; each of the floor and frontwall including at least one panel comprising spaced apart inner andouter shells; and a first curved connector connecting a lower edge ofthe front wall to a front edge of the floor.
 21. The trailer wallconstruction of claim 20, further comprising a generally verticallyextending side wall, and a second curved connector connecting a loweredge of the side wall to a side edge of the floor.
 22. The trailer wallconstruction of claim 21, further comprising a third curved connectorconnecting a side edge of the side wall to a side edge of the frontwall.
 23. The trailer wall construction of claim 22, further comprisinga spherical shaped corner attached to each of the first, second andthird curved connectors.
 24. The trailer wall construction of claim 23,wherein the spherical shaped corner includes spaced apart inner andouter spherical shaped shells.
 25. The trailer wall construction ofclaim 20, wherein the floor includes multiple panels attached to oneanother.
 26. The trailer wall construction of claim 20, wherein thefront wall includes multiple panels attached to one another.
 27. Thetrailer wall construction of claim 20, wherein at least one of the floorand front wall includes multiple panels, the panels being adhesivelybonded to one another.
 28. The trailer wall construction of claim 27,wherein the panels are further welded to one another.
 29. The trailerwall construction of claim 28, wherein the panels are further fastenedto one another using at least one mechanical fastener.
 30. The trailerwall construction of claim 20, wherein at least one of the floor andfront wall includes multiple panels, the panels being welded to oneanother, and wherein the panels are further fastened to one anotherusing at least one mechanical fastener.
 31. The trailer wallconstruction of claim 20, wherein each panel is an aluminum alloyextrusion having multiple spaced apart interior webs extending betweenthe inner and outer shells.
 32. The trailer wall construction of claim20, further comprising a hardenable material positioned within a cavityin at least one of the front wall and the floor.
 33. The trailer wallconstruction of claim 20, further comprising a hardenable materialpositioned within a cavity in the first curved connector. 34-63.(canceled)